Transmission

CLUTCH

MANUAL GEARBOX

DRIVESHAFTS

This document refers to the specifications for the AVANTIME. For all information on sections in common with the ESPACE, refer to Workshop Repair Manual 315.

DE0 T
77 11 304 542 SEPTEMBER 2001
All copyrights reserved by Renault. Copying or translating, in part or in full, of this document or use of the service part reference numbering system is forbidden without the prior written authority of Renault.

EDITION ANGLAISE

"The repair methods given by the manufacturer in this document are based on the technical specifications current when it was prepared. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various component units and accessories from which his vehicles are constructed."

RENAULT 2001

Transmission

Contents
Page

20 CLUTCH
Mechanism - Disc 20-1

21 MANUAL GEARBOX
Gears Lubricants Removal - Refitting 21-1 21-2 21-3

29 DRIVESHAFTS
Removal - Refitting 29-1

CLUTCH 120 Mechanism - Disc

20

SPECIAL TOOLING REQUIRED Mot. 1431 Immobilising tool

Emb. 1604 Clutch refitting tool EQUIPMENT REQUIRED Strut type engine mounting Hydraulic jack

TIGHTENING TORQUES (in daNm) Clutch mounting bolt on the crankshaft Mechanism mounting bolt on the clutch Driveshaft gaiter bolt Shock absorber base bolt Front hub nut Gearbox edge bolt and starter Nut around the gearbox Gearbox mounting bolt on gearbox Wheel bolt REMOVAL Replacement of the L7X PK6 engine and gearbox assembly wear compensation clutch system takes place after removal of the gearbox. Lock in rotation the crankshaft with the flywheel locking tool Mot. 1431 . 3 + 60 1.2 2.4 20 28 5 5 10.5 11

Removal of the whole clutch system: Remove the mechanism (see next page). Remove the six clutch mounting bolts on the crankshaft.

20-1

CLUTCH Mechanism - Disc

20

Removal of the mechanism and the friction: REMOVAL Remove the twelve mechanism mounting bolts. Take out the mechanism and the friction. REFITTING Clean the inside of the plate fully. Check that there are no faults before refitting: excessive or uneven wear, deep grooves, etc...

REFITTING IMPORTANT: clean the mounting holes in the crankshaft and the system bearing face. The friction of the whole new clutch is wedged to let pass a bush and the mounting bolts on the crankshaft. There is no need, therefore, to remove the friction. IMPORTANT: the holes are not equidistant; therefore there is only one position for replacing the clutch on the crankshaft. Tightening torque: 3 daNm + 60.

20-2

CLUTCH Mechanism - Disc

Truss the new mechanism in position using tool Emb. 1604 (several turns of the wheelbrace). Do not insert the friction.

20

Using a screwdriver and with the palm of your hand, tap gently on the valve rockers working on the three systems in turn to distribute the trussing. When the springs are in joined spirals, remove the tool and take care not to knock the mechanism which may cause it to disarm.

20-3

CLUTCH Mechanism - Disc

Fit the disc (offset (A) of the hub flywheel side).

20

Use the clutch centring tool supplied in the kit. Refit the twelve mounting bolts rotating the tightening in a star and lock the bolts. Torque tighten the mechanism mounting bolts: 1.2 daNm. Remove the flywheel locking tool Mot. 1431 and the clutch centring device. After refitting the gearbox, operate the clutch pedal several times to find a normal declutching.

20-4

MANUAL GEARBOX 221 Ratios

Final drive ratio

21
3 rd 4th 5 th Reverse gear

Suffix

Vehicle type

Speedometer gear

1 st

2 nd

PK6 012 DE0 T 17 64 None 11 43 19 40 29 43 39 43 39 35 27 47

21-1

MANUAL GEARBOX Lubricants

CAPACITY (in litres) 2.35 0.15 litres 2.2 0.15 litres

21

New gearbox: If changing the oil, refill

VISCOSITY GRADE TEXACO ETL 8275

1 2

Drain plug Filler plug

WARNING: the filler plug (2) is not an opening that controls the level by overflowing, the incline of the gearbox changes with use in different vehicles. In the event of a leak, drain and refill 2.2 0.15 litres in the gearbox.

21-2

MANUAL GEARBOX Removal - Refitting

EQUIPMENT REQUIRED Strut type engine mounting Hydraulic jack

21

REMOVAL TIGHTENING TORQUES (in daNm) Driveshaft gaiter bolt Shock absorber base bolt Front hub nut Gearbox edge and starter motor bolt Nut around the gearbox Gearbox mounting bolt on gearbox Wheel bolt CONSUMABLES MOLYKOTE BR2: Splines of the right-hand sunwheel and relaybearing exterior race 2.4 20 28 5 5 10.5 11 Put the car on a two-post lift. Disconnect and remove the battery. Remove: the front wheels, the engine undertray, the left hand wheel arch protector.

21-3

MANUAL GEARBOX Removal - Refitting

Drain the gearbox. Refit the drain plug with a new seal. Disconnect the ABS target sensor. TO REMOVE THE DRIVESHAFTS: Push away the driveshafts. Right-hand side of the vehicle Remove: the two mounting bolts (1) at the base of the shock absorber on the stub-axle,

21

Unfasten the wear warning strip wire from the brake pads.

WARNING: these driveshafts are not cemented and should not be on refitting. Tilt the stub-axle carrier to remove the splined shaft and remove the driveshaft.

the two transmission flange mounting bolts on the relay bearing.

Take care to protect the gaiters.

21-4

MANUAL GEARBOX Removal - Refitting

Left-hand side of the vehicle Carry out the same procedure for the right-hand side, except: Remove the three driveshaft gaiter bolts.

21

If necessary, fit the pedal press on the clutch pedal, lightly depressed. Disconnect the valve (3) from the clutch slave cylinder; be ready for the brake fluid running out. Unclip the two passage (4) and selection (5) cables from the gearbox by pressing on their central unlocking button.

Remove the driveshaft; take care of the gaiters. In the engine compartment: Remove: the air filter unit, the air filter mounting, the flexible air inlet duct (2).

With a pair of pliers, unfasten the retaining clips on the sleeve stops (6), pinch them and pull upwards.

21-5

MANUAL GEARBOX Removal - Refitting

Disconnect and remove the TDC sensor (7). Separate the electrical sleeve from the retaining clip (8). Temporarily fit this sleeve to the rear to avoid jamming it when fitting the gearbox. Remove the two bolts and the two gearbox housing upper mounting studs (A) on the engine. Under the vehicle:

21

Put a stay fitted with a rubber base under the engine oil housing (on the clutch housing side) and a component jack under the gearbox.

Remove: the catalytic converter connection clip,

21-6

MANUAL GEARBOX Removal - Refitting

the oxygen sensor (9) to make removing/refitting the gearbox easier.

21

IMPORTANT : watch the angle to avoid colliding with the cooling unit or the right-hand section under the side member. Never leave the engine suspended without a support stay because it may damage the engine suspensions. Remove the last two mounting bolts on the engine. To facilitate the removal of the gearbox, pivot it round the shifter shaft by lifting the final drive upwards.

Remove the two bolts and the two retaining fork mounting studs (10) on the gearbox.

Carefully lower the engine and gearbox assembly by lifting the vehicle.

21-7

MANUAL GEARBOX Removal - Refitting

REFITTING Proceed in the reverse order to removal. Adjusting the gear shift: Unclip the front central console trim (7) and pull it upwards by the rear section, then release it to the rear.

21

Fix the sleeve stops (3) and (4) with their clip and refit ball joint (1) only. WARNING: do not fit ball joint (2).

Check that the gearbox selection lever (12) positions naturally in neutral (approximately vertical).

Remove the gear lever gaiter and its base.

21-8

MANUAL GEARBOX Removal - Refitting

Clip the ball joint on the selector lever without locking the cable/end-piece connection system.

21

In the engine compartment, lock the end-piece/cable connection system in this position at the same time resting on and below the moving valve rocker, to balance the effort and avoid bending the cable.

Put the lever adjustment jig (13) on the control lever, and press on the lever trim housing. Remove the adjustment jig. Check that the gears change correctly. Refitting is the reverse of removal.

21-9

DRIVESHAFTS 329 Removal - Refitting

29

The side driveshafts of the AVANTIME are the same as on the latest model of the ESPACE, they are no longer cemented and should not be cemented on refitting. TIGHTENING TORQUES (in daNm) Driveshaft gaiter bolt Shock absorber base bolt Front hub nut Wheel bolt CONSUMABLES MOLYKOTE BR2: Splines of the right-hand sunwheel and relaybearing exterior race 2.4 20 28 11 Drain the gearbox. Refit the drain plug with a new seal. Right-hand side of the vehicle Remove: the two mounting bolts (1) at the base of the shock absorber on the stub-axle,

REMOVAL Put the car on a two-post lift. Disconnect the battery. Remove: the front wheels, the front wheel arch covers.

29-1

DRIVESHAFTS Removal - Refitting

the two transmission flange mounting bolts on the relay bearing. Left-hand side of the vehicle

29

Carry out the same procedure for the right-hand side, except: Remove the three driveshaft gaiter bolts.

Unfasten the wear warning strip wire from the brake pads. Disconnect the ABS target sensor. Push away the driveshafts. WARNING: these driveshafts are not cemented and should not be on refitting. Tilt the stub-axle carrier to remove the splined shaft and remove the driveshaft.

Remove the driveshaft; take care of the gaiters. On refitting, tightening torque on the hub nut: 28 daNm.

Take care to protect the gaiters.

29-2